Modular kitchen component system

ABSTRACT

A kitchen sink top is produced to a standard size selected from one or more predetermined standard sizes. The kitchen sink top is formed from natural stone or other homologous stone-effect material and, during production, is formed with an aperture suitable for an undermount-type sink bowl, at least one aperture for mounting a tap or faucet, and a recessed drainage area adjacent the sink bowl aperture. A modular kitchen component system, a method of producing the sink top, and an extension or backsplash element are also provided.

BACKGROUND OF THE INVENTION

The present invention relates to a modular kitchen component system, akitchen sink top, an extension or backsplash element, and to a method ofproduction.

Modular kitchen component systems are already well known and widelyavailable from home improvement centres and such like. These areprovided with tops, such as sink tops and counter tops, which aregenerally wood, for example chipboard, and a laminate surface adheredthereto. To date, only wood-based tops have been able to be provided aspart of a modular kitchen component system.

Tops formed from other materials, such as natural stone, have to bepre-ordered and individually custom designed. This is expensive and thusoften prohibitive to a person installing a new kitchen.

It should be understood that, although reference is made throughout to‘kitchen’ this is intended to include any preparation area requiringsink access. For example, the ‘kitchen’ could be a bar area, restaurant,laboratory, galley of a ship or indeed any food preparation area.

U.S. Pat. No. 6,594,973 has gone some way to addressing the aboveproblem. This document suggests pre-cut stone tops being supplied tohigh volume home improvement centres. However, problems arise due to the‘one size fits all’ approach taken, and no solution is provided toenable such a worktop to be incorporated as part of a modular kitchencomponent system. Furthermore, multiple orientation of the worktop isnot provided for, nor are drainage requirements for washed articlestaken into account.

The present invention seeks to provide a solution to all of theabove-mentioned problems.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided akitchen sink top which is produced to a standard size selected from oneor more predetermined standard sizes, the kitchen sink top being formedfrom natural stone or other homologous stone-effect material and, duringproduction, being formed with an aperture suitable for anundermount-type sink bowl, at least one aperture for mounting a tap orfaucet, and a recessed drainage area adjacent the sink bowl aperture.

Preferably, the sink top is produced as part of a batch of identical orsubstantially identical sink tops.

The term ‘batch’ is defined as being two or more, and includes bulk- andmass-production. Batch production of the tops is advantageous in thatexpensive unique templates produced from a site survey by a skilledtradesman can be dispensed with.

According to a second aspect of the invention, there is provided akitchen sink top which is produced to a standard size selected from oneor more predetermined standard sizes, the kitchen sink top being formedfrom natural stone or other homologous stone-effect material and which,during production, is formed with an aperture suitable for anundermount-type sink bowl, and two apertures for mounting a tap orfaucet, one of the two tap or faucet apertures being provided adjacent afirst edge of the sink top and the other of the two tap or faucetapertures being provided adjacent a second different edge of the sinktop, so that the sink top can be installed in two differentorientations.

According to a third aspect of the invention, there is provided a methodof batch-producing kitchen sink tops, the method comprising the stepsof:

-   -   a. supplying a first location with slabs of quarried natural        stone and/or sheets of homologous stone-effect material;    -   b. sizing one said slab or sheet to a standard size selected        from one or more predetermined standard sizes at the first        location;    -   c. forming in the one slab or sheet an aperture suitable for an        undermount-type sink bowl at the first location;    -   d. forming in the one slab or sheet at least one aperture for        mounting a tap or faucet at the first location;    -   e. forming in the one slab or sheet a recessed drainage area        adjacent the sink bowl aperture at the first location;    -   f. finishing the sink top at the first location;    -   g. repeating steps (a) to (f) to form at least one further        identical or substantially identical kitchen sink top; and    -   h. supplying at least one of the finished kitchen sink tops to a        second location ready for installation.

According to a fourth aspect of the invention, there is provided anextension or backsplash element which is formed from natural stone orother homologous stone-effect material and which is for use with akitchen countertop or worktop, the extension or backsplash elementhaving two rear surfaces which extend transversely to each other, and afront face, the two rear surfaces having different dimensions so thatthe extension or backsplash element can be installed in either of twoorientations to cover a gap between a wall and an edge of an installedkitchen countertop or worktop.

According to a fifth aspect of the invention, there is provided a methodof producing an extension or backsplash element for use with a kitchencountertop or worktop, the method comprising the steps of

-   -   a. supplying a first location with quarried natural stone or        homologous stone-effect material;    -   b. sizing the stone or stone-effect material to a standard size        selected from one or more predetermined standard sizes at the        first location;    -   c. forming the extension or backsplash element from the sized        material at the first location;    -   d. supplying the extension or backsplash element to a second        location.

According to a sixth aspect of the invention, there is provided amodular kitchen component system comprising a sink unit having a sinktop in which is provided one or more pre-formed apertures for anundermount-type sink and which is reversible to allow installation ineither of two different orientations; a corner unit having a corner top;a standard unit having a standard top; an extension or backsplash unithaving internal and/or external corners; end profile units having endprofile tops; and hob slip units having hob slip tops, each said topbeing produced to a standard size selected from one or morepredetermined standard sizes and formed from natural stone or otherhomologous stone-effect material at a production location remote from aninstallation location at which the modular kitchen component system isto be installed.

The present invention will now be more particularly described, by way ofexample only, with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective schematic view of part of one embodiment of amodular kitchen component system, in accordance with the seventh aspectof the invention;

FIG. 2 shows a perspective view of a top of a corner unit suitable foruse with the modular component system shown in FIG. 1;

FIG. 3 shows a perspective view of a marketing badge for use with akitchen sink top, in accordance with the second aspect of the invention;

FIG. 4 shows a plan view of a standard top for use with the modularkitchen component system shown in FIG. 1;

FIG. 5 shows a transverse sectional end view of an extension orbacksplash element, in accordance with the fifth aspect of the inventionand which is suitable for use with the modular kitchen component systemshown in FIG. 1;

FIG. 6 is a transverse sectional end view showing the extension orbacksplash element shown in FIG. 5 arranged in a first condition on thestandard top shown in FIG. 4;

FIG. 7 is a transverse sectional end view showing the extension orbacksplash element shown in FIG. 5 arranged in a second condition on thestandard top shown in FIG. 4;

FIG. 8 is a scrap perspective view of an end profile top shown in FIG.1;

FIG. 9 shows an end view of the standard top shown in FIG. 4;

FIG. 10 shows an end view of the hob slip top shown in FIG. 1; and

FIG. 11 shows an enlarged perspective view of the hob slip top shown inFIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, there is shown a modular kitchen componentsystem which comprises a sink unit having a sink top 1, a corner unithaving a corner top 2, a standard unit having a standard top 3,extension or backsplash elements 4, which at a corner have an internalcorner 5 or an external corner (not shown), an end profile unit havingan end profile top 6, and front and rear hob slip tops 7 & 8.

The sink top 1 is produced from a rectangular slab of natural stone orother homologous stone-effect material. The sink top 1 has profilededges 9 on two parallel sides whose distance apart is equal to the widthof the standard top 3 plus the additional length of a profiled edge 9when viewed on plan. The length which will be dependant on the numbersof sinks and any design features such as a drainage area 10 and drainagegrooves 11. The thickness of the sink top 1 will be a standard thicknessof slab or sheet, typically in the range of 20 millimetres (mm) to 60mm.

The front-to-back width of the sink top 1 will be greater than that ofthe other modular tops, but is likely to be no more than 15 millimetres(mm) greater. This small addition in width can be accommodated withinthe structure of the building and is normally contained within theplaster or plasterboard thickness of the mounting wall. Alternatively,this small addition can be removed on-site. This extra width allows theface edges of adjacent tops to run through in the same plane when viewedon plan.

The sink top 1 in addition to one or more off-centre sink bowl apertures1 a has design features such as the sunken or recessed drainage area 10and drainage grooves 11. The or each sink bowl aperture 1 a is suitablefor an undermount-type sink bowl only.

By providing two tap or faucet apertures 12, one adjacent an edge 9 a ofthe sink top 1 and the other adjacent a parallel edge 9 b, the sink top1 can be installed in two different orientations with the drainage area10 extending to the left or right of the or each sink bowl aperture 1 a.The orientation of the sink top 1 determines which of the two tap orfaucet apertures 12 is redundant after installation of a mono block tapor faucet (not shown). The aperture 12 which does not contain the monoblock tap can be used for a pop up waste control, a soap dispenser or amarketing badge 14, shown in FIG. 3.

The edges 9 a and 9 b of the sink top 1 have profiled faces. However,only one of the edges 9 a and 9 b need be profiled.

FIG. 2, shows a corner top 2 a having a different shape. This top 2 a isformed from a rectangular piece of stone or stone-effect material havingsides greater in length than the width of the top. The thickness is astandard thickness of slab or sheet material. As with the sink top 1,the corner tops 2 and 2 a have at least one profiled edge 9. Two buttjoints 13, which are perpendicular to the profiled edge 9, allows forthe adjacent top to have the same perpendicular edge.

Although not shown, the corner top 2 a could contain a sink bowlaperture.

FIG. 3 shows the marketing badge 14, which is of a diameter greater thanthe tap or faucet aperture 12. The badge 14 is approximately 2-3 mmthick and formed of stainless steel to match the tap and/or theundermount sink when attached. A plug 15 is attached to the underside ofthe badge 14. The plug 15 fits the tap or faucet aperture 12, and isheld in position by friction or adhesive.

FIG. 4 shows the standard top 3 for the standard unit. The standard top3 is rectangular in shape, and has a width equal to that of a standardunit. The length of the standard top 3 is pre-selectable and limitedonly by the variety of chosen stone. The thickness of the standard top 3is a standard thickness of slab sold within the Industry.

The standard top 3 has at least one profiled edge 9 and two butt joints13, which are perpendicular to the profiled edge 9. It is the standardtop 3 which accommodates the variables of the widths and lengths of theother tops. The standard top 3 is cut to length on-site to interfacebetween the other units and tops.

It is the intention of this invention to limit any on-site cutting tothat which can be performed to a satisfactory standard on-site usinghand held machinery.

Furthermore, it is intended that the length of any on-site cut belimited to the width of the standard top 3.

A company that provides such machinery for this task is AlphaProfessional Tools of 250, Braen Avenue, Wyckoof, N.J. 078481 USA whichhave world wide distributors. The machine, the AWS-110, comes with aguide carriage and guide rail as optional extras. These extras would beneeded to ensure that the new cut edge is perpendicular to the faceprofiled edge.

FIG. 5 shows the extension or back splash element 4 which is producedfrom a rectangular section of natural stone or other homologousstone-effect material. having unequal sides, approximately in the ratioof 3:1 to 4:1.

The extension or backsplash element 4 has a contoured, sculpted orprofiled front face 16. The front face 16 may be concave as shown inFIG. 5, or convex. The extension or backsplash element 4 has two rearsurfaces 4 a which extend transversely, preferably perpendicularly, toeach other. The two rear surfaces 4 a have different dimensions.

The return sides 17 of the extension or backsplash element 4 have adimension which exceeds the combined thickness of a standard ceramicwall tile and the thin bed adhesive used to fix the tiles to the wall.

FIG. 6 shows a section through the extension or backsplash element 4 anda standard top 3 having a profiled edge 9 shown here as a semi bulnose,and wall tiling 18. The extension or backsplash element 4 is shown hereas a vertical back splash used to cover a small gap between the mountingwall and the adjacent edge of the standard top 3.

FIG. 7 shows a similar section through an extension or backsplashelement 4 and a standard top 3 having profiled edge 9 shown here as afull bulnose, and wall tiling 18 The extension or backsplash element 4is shown here as an extender to extend the width of the standard top 3to cover a larger gap between the mounting wall and the adjacent edge ofthe standard top 3.

The extension or backsplash element 4 can be provided in straightlengths or with an internal corner 5 (see FIG. 1), or with an externalcorner (not shown). This prevents the need for on-site mitring to allowthe extension or backsplash element 4 to extend around corners of thesupporting wall surface.

FIG. 8 shows the end profile top 6 of the end profile unit. This top 6is provided adjacent the standard top 3 and an extension or backsplashelement 4. A timber batten 19 is optionally used for support of theextension or backsplash element 4.

The end profile top 6 has two profiled edges 9 at 90 degrees to oneanother.

The end profile top 6 is produced from a rectangular piece of stone orhomologous stone-effect material, the minimum width of which allows forthe profile size plus the dimension equal to the radius of supportingdiscs 21 held in slots 20.

The thickness of the end profile top 6 is a standard thickness of slabor sheet of material

The length of the slots 20 is less than the width of the hob slip tops 7and 8. The height of the slots 20 is marginally greater than thethickness of the supporting discs 21 to allow an adhesive to fill andset. The depth of the slots 20 is not less than the radius of thesupporting discs 21, as it intended that 50% of each disc 21 lies withinthe end profile top 6 and the adjacent top when fixed.

The vertical & horizontal centre lines of the slots 20 are standardisefor all tops as shown in FIGS. 9 and 10. The end profile top 6 is usedto finish an open end of a sink top 1, corner top 2, standard top 3, orhob slip tops 7 and 8.

The end profile top 6 can be cut to length if need be, as describedabove. It can be adhered to the adjacent top by means of a polyesterresin or an epoxy resin two part adhesive. Adhesives are widelyavailable through the international stone industry. Akemi and Fidal aretwo well established trade names of these adhesives with world widedistribution.

A standard top 3 is shown in FIG. 9, and this arrangement is alsotypical for corner tops 2, sink tops 1 and end profile tops 6. Two slots20 are provided on or substantially on the centreline X.

FIG. 10 shows an end view of the front and rear hob slip tops 7 and 8.The term ‘slip top’ means a top in or on which a hob, cooker or burnerunit is mounted, and is also commonly referred to as a ‘cooker top’. Twoslots 20 are again provided on the centreline X.

Both front hob slip top 7 and rear slip top 8 are produced from arectangular area of stone, or stone-effect material as mentioned above,having similar or identical widths, as most hob or drop-in-cooker unitsare produced to be incorporated into standard size countertops with goodtolerances, so it is envisaged that the widths of the hob slips can bestandardised.

The thickness of the hob slip tops 7 and 8 are a standard thickness ofslab or sheet. The front hob slip 7 has the profiled edge 9. The lengthof both the front and rear slip tops 7 and 8 is a variable dependantupon the length of the hob (cooker drop in units) but it is envisagedthat it will be standardised into two or three lengths equating to 4, 6,or 8 ring hobs.

Each of the tops 1, 2, 3, 6, 7 and 8 described above is produced bysupplying a first location with quarried natural stone or homologousstone-effect material. The natural stone is, by way of example, granite,marble, limestone, sandstone, slate or serpentine. The stone-effectmaterial is, by way of example, micro-grain marble or other polymerbased material such as Corian RTM or Surell RTM.

Preferably, the stone or stone-effect material supplied to the firstlocation is already in slab or sheet form. However, it may be suppliedin a form requiring slabbing.

The stone or stone-effect material is sized at the first location to astandard size selected from one or more predetermined standard sizes. Inthe case of the sink top 1, the sink bowl aperture or apertures 1 a andat least one tap or faucet aperture 12 are then formed in the sink top1, still at the first location. The recessed drainage area 10 adjacentthe sink bowl aperture(s) 1 a is also formed at the first location.

The top is then finished at the first location before it is supplied toa second location ready for installation. The second location may be,for example, a distributor, a customer's premises, or a wholesaler.

The tops 1, 2, 3, 6, 7, 8 are batch produced at the first location forsupply to second installation locations. Different batches will beproduced to pre-selected standard sizes, allowing a degree of mixing andmatching to suit most, if not all, installation environments.

It is envisaged that the consumer will select the required unitsincluding tops, and sizes from the given standard sizes, in addition totaps or faucets and one or more undermount-type sinks suitable for theaperture or apertures 1 a in the sink top 1. This allows the consumer tohave a degree of flexibility, while still allowing batch production. Atleast the tops 1, 2, 3, 6, 7, 8 will then be supplied from the firstlocation from amongst a pre-produced batch of standard tops.

The batch production of tops 1, 2, 3, 6, 7 and 8, including sizing,aperture forming, recessing and finishing, can conveniently be performedby CNC machinery. These processes can thus be automated, and a standardsize for a batch of identical or substantially identical tops can beselected from one or more predetermined standard sizes.

Similarly, the extension or backsplash element 4 can be batch produced.As described above, the extension or backsplash element 4 is produced bysupplying a first location with quarried natural stone or homologousstone-effect material. The natural stone is, by way of example, granite,marble, limestone, sandstone, slate or serpentine. The stone-effectmaterial is, by way of example, micro-grain marble or other polymerbased material such as Corian RTM or Surell RTM.

Preferably, the stone or stone-effect material supplied to the firstlocation is already in slab or sheet form. However, it may be suppliedin a form requiring slabbing.

The stone or stone-effect material is sized at the first location to astandard size selected from one or more predetermined standard sizes. Ifinternal corners 5 or external corners are required, these are formed atthe first location.

The extension or backsplash element 4 is then finished at the firstlocation before it is supplied to a second location as above.

The extension or backsplash elements 4 are batch produced at the firstlocation for supply to second installation locations. Different batcheswill be produced to one or more pre-selected standard sizes, allowing adegree of mixing and matching to suit most, if not all, installationenvironments.

The batch production of the extension or backsplash elements 4,including sizing, corner forming, and finishing, can conveniently beperformed by CNC machinery. These processes can thus be automated, and astandard size for a batch of identical or substantially identicalextension or backsplash elements 4 can be selected from one or morepredetermined standard sizes.

Of course, the batch processes performed by the CNC machinery could bebatch performed by hand.

It is preferable, although not essential, that the taps or faucets andundermount sink bowl or bowls selected by the consumer, along with thebase carcasses of the units for the tops all be supplied to the consumerfrom the first location.

Finishing can also be performed at a different location, for example atthe installation location.

By the method described above, it is possible to have a run producingonly a single unique top or tops. It is also possible to produce a sinktop having the undermount sink bowl aperture, the recessed drainage areaand only one tap or faucet aperture. In this case, the sink top will notbe reversible.

Alternatively, a sink top having an undermount sink bowl aperture andtwo tap or faucet apertures, without the recessed drainage area ispossible.

Additionally, the above-described tops can be produced independently ofeach other, for example, the sink top does not have to be producedsolely for the inclusion as part of a modular kitchen component system.Similarly, the extension or backsplash element can be producedseparately of the tops and does not have to be included and used as partof a modular kitchen component system.

The embodiments described above are given by way of examples only, andmodifications will be apparent to persons skilled in the art withoutdeparting from the scope of the invention as defined by the appendedclaims.

1. A kitchen sink top which is produced to a standard size selected fromone or more predetermined standard sizes, the kitchen sink top beingformed from natural stone or other homologous stone-effect material and,during production, being formed with an aperture suitable for anundermount-type sink bowl, at least one aperture for mounting a tap orfaucet, and a recessed drainage area adjacent the sink bowl aperture. 2.A kitchen sink top as claimed in claim 1, wherein two tap or faucetapertures are provided, one of the said tap or faucet apertures beingpositioned adjacent a first edge of the sink top and the second said tapor faucet aperture being positioned adjacent a second different edge ofthe sink top, the citing of the tap or faucet apertures allowing thesink top to be installed in two different orientations.
 3. A kitchensink top as claimed in claim 1, wherein at least one edge of the sinktop is profiled.
 4. A kitchen sink top as claimed in claim 1, whereinthe sink top is produced as part of a batch of identical orsubstantially identical sink tops.
 5. A kitchen sink top as claimed inclaim 1, further comprising an undermount-type sink bowl.
 6. A kitchensink top which is produced to a standard size selected from one or morepredetermined standard sizes, the kitchen sink top being formed fromnatural stone or other homologous stone-effect material and which,during production, is formed with an aperture suitable for anundermount-type sink bowl, and two apertures for mounting a tap orfaucet, one of the two tap or faucet apertures being provided adjacent afirst edge of the sink top and the other of the two tap or faucetapertures being provided adjacent a second different edge of the sinktop, so that the sink top can be installed in two differentorientations.
 7. A kitchen sink top as claimed in claim 6, furthercomprising a recessed drainage area adjacent the sink bowl aperture, therecessed drainage area being formed in the natural stone or otherhomologous stone-effect material.
 8. A kitchen sink top as claimed inclaim 6, wherein at least one edge of the sink top is profiled.
 9. Akitchen sink top as claimed in claim 6, wherein the sink top is producedas part of a batch of identical or substantially identical sink tops.10. A kitchen sink top as claimed in claim 6, further comprising anundermount-type sink bowl.
 11. A method of batch-producing kitchen sinktops, the method comprising the steps of: a. supplying a first locationwith slabs of quarried natural stone and/or sheets of homologousstone-effect material; b. sizing one said slab or sheet to a standardsize selected from one or more predetermined standard sizes at the firstlocation; c. forming in the one slab or sheet an aperture suitable foran undermount-type sink bowl at the first location; d. forming in theone slab or sheet at least one aperture for mounting a tap or faucet atthe first location; e. forming in the one slab or sheet a recesseddrainage area adjacent the sink bowl aperture at the first location; f.finishing the sink top at the first location; g. repeating steps (a) to(f) to form at least one further identical or substantially identicalkitchen sink top; and h. supplying at least one of the finished kitchensink tops to a second location ready for installation.
 12. A method asclaimed in claim 11, wherein step (b), step (c), step (d), step (e),and/or step (f) are performed utilising a machining process.
 13. Amethod as claimed in claim 12, wherein the machining process isautomated.
 14. A method as claimed in claim 11, wherein, in step (h),the finished kitchen sink top and an undermount-type sink bowl aresupplied to the second location.
 15. An extension or backsplash elementwhich is formed from natural stone or other homologous stone-effectmaterial and which is for use with a kitchen countertop or worktop, theextension or backsplash element having two rear surfaces which extendtransversely to each other, and a front face, the two rear surfaceshaving different dimensions so that the extension or backsplash elementcan be installed in either of two orientations to cover a gap between awall and an edge of an installed kitchen countertop or worktop.
 16. Anextension or backsplash element as claimed in claim 15, wherein thefront face is at least one of sculpted, profiled, convex and concave.17. An extension or backsplash element as claimed in claim 15, furthercomprising an internal and an external corner to allow extension arounda corner of a supporting surface.
 18. A method of producing an extensionor backsplash element for use with a kitchen countertop or worktop, themethod comprising the steps of a. supplying a first location withquarried natural stone or homologous stone-effect material; b. sizingthe stone or stone-effect material to a standard size selected from oneor more predetermined standard sizes at the first location; c. formingthe extension or backsplash element from the sized material at the firstlocation; d. supplying the extension or backsplash element to a secondlocation.
 19. A method as claimed in claim 18, further comprising a step(e) between step (c) and step (d) of finishing the extension orbacksplash element at the first location.
 20. A method as claimed inclaim 18, wherein steps (a) to (d) are repeated to produce a batch ofextension or backsplash elements to a single pre-selected standard size.21. A method as claimed in claim 18, wherein step (b), step (c) and/orstep (e) are performed utilising a machining process.
 22. A method asclaimed in claim 21, wherein the machining process is automated.
 23. Amodular kitchen component system comprising a sink unit having a sinktop in which is provided one or more pre-formed apertures for anundermount-type sink and which is reversible to allow installation ineither of two different orientations; a corner unit having a corner top;a standard unit having a standard top; an extension or backsplash unithaving internal and/or external corners; end profile units having endprofile tops; and hob slip units having hob slip tops, each said topbeing produced to a standard size selected from one or morepredetermined standard sizes and formed from natural stone or otherhomologous stone-effect material at a production location remote from aninstallation location at which the modular kitchen component system isto be installed.
 24. A system as claimed in claim 23, further comprisingan undermount-type sink for attachment to the sink top of the sink unit.25. A system as claimed in claim 23, wherein the said tops have at leastone profiled edge.
 26. A system as claimed in claim 23, wherein the saidtops are finished at the production location.
 27. A system as claimed inclaim 23, wherein the said tops are batch-produced to the said selectedstandard size.
 28. A system as claimed in claim 23, wherein the sink topincludes a recessed drainage area formed in the natural stone or otherhomologous stone-effect material.